Application Note Harris June, 1999 Waferscale Integrati

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Application Note Harris June, 1999 Waferscale Integrati

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In-System Programmability- Much Money Save?
Application Note
Harris
June, 1999
Waferscale Integration, Inc. 47280 Kato Road, Fremont, 94538 Telephone: (510)-656-5400 (800) TEAM-WSI (832-6974) Site: http://www.waferscale.com E-mail: info@waferscale.com
In-System ProgrammabilityHow Much Money Save?
Harris June, 1999
Abstract
This document illustrates integrated-circuit devices that In-System Programmable save money reduce your time-to-market. look well beyond initial purchase price device track cost ownership over lifetime. will that save time money throughout lifecycle part-from development manufacturing updates upgrades.
Contents
Introduction Assumptions Development Phase Manufacturing Phase. Update/Upgrade Phase
Waferscale Integration, Inc. Fremont 800-832-6974 www.waferscale.com
Introduction
In-System Programmable (ISP) devices provide major technological advantage that reduce time-to-market save money. With ISP, blank device soldered directly circuit board programmed re-programmed time. Because socket required, device need only handled once lifetime. This document compares cost ownership part versus traditional method prototyping with "windowed" EPROM-based part going into production with One-Time Programmable (OTP) part. typical lifecycle electronic product follows:
evelopm hase anufacturing hase pdate/U pgrade hase
Each phase discussed separate section shows save money reduce your time-to-market. Until recently, been used mainly loading fuse maps into programmable logic devices. However, with today's increased microcontrollers (MCUs), being used other applications. addition programmable logic, being used program firmware into memory from which will operate. Waferscale offers PSD8XXF family peripheral devices. This family contains devices that integrate both programmable logic nonvolatile memory (NVM) same die. PSD8XXF devices 100% through IEEE 1149.1 compliant JTAG channel. PSD8XXF family unique industry. only family offer that directly programmable through JTAG channel. This important because many systems already using JTAG testing because simplicity overhead. Now, entire product programmed (including firmware) tested over single communication channel. Equally important: download software written debugged, separate device programmer required achieve ISP. addition JTAG, PSD8XXF also offers other methods achieve save costs reduce time-to-market. Let's look details.
Assumptions
following assumptions used basis comparison product versus non-ISP product. lifetime product five years Over five year period, 10,000 units will produced average cost each unit $1000 Each unit takes hour disassemble hour reassemble average rate technician hour (including benefits) fallout socketed parts mishandling 33%.
Waferscale Integration, Inc. Fremont 800-832-6974 www.waferscale.com
Development Phase
development phase, can: Reduce up-front costs Eliminate need socket Reduce overall development time. Up-Front Costs There up-front costs associated with traditional development using EPROM-based windowed part: stand-alone device programmer, ranging price between $300 $3000. eraser, averaging around $50. These costs would incurred per-station basis. Note: cost programmer increase substantially ability program more than part time. With JTAG compliant parts, only single cable that plugs into standard parallel port required. This cable program part many parts they connected chain configuration. cost this cable Waferscale's Flash-based PSDs Eliminate Sockets nature ISP, design iterations handled in-system. Therefore, blank devices soldered directly onto circuit board. This eliminates need sockets devices. This case with windowed EPROM parts. socket required throughout lifecycle unit. average 1000-piece1 price different 52-pin sockets from five different manufacturers found $1.17 socket. This cost added each unit made. Therefore, sockets 10,000 units would extra $11,700 overall production cost. design won't allow socket because electrical loading, cost issues, hostile environments, de-soldering re-soldering part each time contents change would required. This would only tremendous design time, each circuit board become unworkable after only iterations. This could tremendous cost design, which could avoided with part. Development Time reduces time-to-market. Since each design environment different, difficult produce exact numbers regarding time reduction. However, information provided here should make clear that time-to-market will reduced.
1000 piece pricing used because 10,000 parts would ordered over period five years, 1000 pieces time.
Waferscale Integration, Inc. Fremont 800-832-6974 www.waferscale.com
design cycle windowed EPROM-based part shown below.
(take
With ISP, simply update device using programming cable connected your circuit board. Notice three steps eliminated using this method, saving vast amounts time during development. Also, since there handling device with ISP, there will fallout damaged parts. PSD8XXF family saves development debug time providing JTAG channel program firmware directly into Flash memory. traditional method downloading firmware Flash memory in-system through UART channel controlled MCU. such, code implement UART download Flash memory must developed debugged before real application code written. Download code difficult create because developing code deposit code into memory. Until code into memory, can't debug code that gets there. With PSD8XXF family, does have develop this download code front. Simply connect JTAG download cable program part. This implies designer start writing application code immediately, without having worry about writing download code.
Manufacturing Phase
There critical factor that will save time money during manufacturing: devices have programmed until board tested! That fact leads following: Many manufacturing steps eliminated Excess inventory eliminated Design revisions require parts wasted Quality problems reduced. These factors lead higher yield less time. Figure (next page) shows manufacturing steps eliminated when manufacturing with versus parts.
Waferscale Integration, Inc. Fremont 800-832-6974 www.waferscale.com
anufacturing Flow Parts
lank vices from
anufacturing Flow Parts
lank from
gram vice gram
eturn vices
ring gram
ssem
ssem
Figure 1-Manufacturing Flow with versus parts first thing notice with that programming each part front with stand-alone programmer required. Programming part delayed until just before entire assembly tested. PSD8XXF JTAG interface allows device programmed using inexpensive cable that attaches parallel port. this cable download manufacturing test code, then again load final application code. Alternately, commercial Automated Test Equipment (ATE) (manufactured GenRad, others) used program PSD8XXF over JTAG channel. this case, other non-PSD8XXF JTAG devices that reside printed circuit board tested programmed well. seen from flowchart, manufacturing with parts requires four fewer steps compared manufacturing with parts. Manufacturing with Eliminates Excess Inventory Using during manufacturing eliminate excess inventory following reasons: separate inventories separate versions software required. Manufacturing with parts normally requires extra parts kept hand case there last minute software changes. Products "made-to-order" demand dictates.
Waferscale Integration, Inc. Fremont 800-832-6974 www.waferscale.com
Eliminates Wasted Parts Imagine following scenario: your company ready ship units when unacceptable software discovered. With parts, would have throw away programmed parts start beginning manufacturing flow. With ISP, simply need reprogram device with software. Manufacturing with Reduces Quality Problems Since devices soldered directly circuit board, socket will required, previously discussed. Because there socket involved part programmed until test time, following quality problems eliminated: Bent leads when inserting devices into sockets Putting part with wrong software version into socket Installing devices into sockets with incorrect orientation Installing wrong device multiple sockets. This section showed that simply waiting program part until unit ready testing reduces manufacturing steps, eliminates excess inventory, reduces quality problems. This translates into huge cost savings reduced time-to-market.
Update/Upgrade Phase
This where parts really excel cost savings over traditional methods. Updating upgrading part quite costly complicated, depending path chosen. Some manufacturers simply choose scrap product field send replacement. Since assumed each unit costs $1000 build, would cost $10,000,000 update/upgrade units. Alternately, product recalled update. (See right-hand column Figure next page.) products using PSD8XXF device, updates upgrades very easy perform. disassembly product required load firmware configuration into product. fact, depending product, these upgrades updates done remotely over Internet other communication medium. PSD813F offers methods upgrade products field. JTAG, other using concurrent memory arrays inside PSD8XXF. When JTAG used, does need participate way. When concurrent memory used, operates from memory while writing (upgrading) other. This method allows updates upgrades done over communication channel available MCU. (Examples include Ethernet, modem, CAN, RS-232, RS-485.) Concurrent memory operation allows continue some system functions during ISP, which critical some applications. example, production-line controller, crucial continue control process during prevent accident injury. With devices, more options available handle field updates upgrades, including:
Waferscale Integration, Inc. Fremont 800-832-6974 www.waferscale.com
Upgrade products remotely over communication channel. Send service person customer site upgrade with laptop computer. Recall products upgrade them factory disassembly needed). Note that first option available parts. simplicity, let's assume that product recalled. Below, Figure compares part update (left) part update (right).
Update/Upgrade
Custom sends unit update/upgrade
pdate/Upgrade
Custom sends unit update/upgrade
Technician disassem bles unit hour
Technician connects program cable unit negligible
Technician oves part from socket de-solders part de-soldered)
Technician gets part from inventory available) inutes
Technician program s/verifies part in-system negligible
Technician program verifies part program negligible
Technician puts part into socket solders part inutes soldered)
Technician re-assem bles unit hour
Technician tests unit
Technician tests unit
Technician sends unit back custom
Technician sends unit back custom
Figure 2-ISP update/upgrade versus update/upgrade compare times flowcharts, that unit with part inside will require extra three quarter hours technician work. hour, this equates $195 unit. 10,000 units recalled updated because software, total would come $1,950,000 extra!
Waferscale Integration, Inc. Fremont 800-832-6974 www.waferscale.com

Application Note Harris June, 1999 Waferscale Integrati

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